6 - Speed manual gearbox 0AJ

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Identification on the gearbox
  1
• 1.2 Prefix, correspondence, gear ratio, filling volumes
  2
• 2 Gearbox - overview
  3
• 3 Gear ratio calculation “i”
  5
• 4 Safety indications
  6
• 5 General repair instructions
  7
• 5.1 Components
  7
• 6 Electric components
  12
• 6.1 Electric components - assembly overview
  12
• Clutch
  14
• 1 Clutch control
  14
• 1.1 Clutch drive system - assembly locations overview
  14
• 1.2 Clutch drive pedal - assembly overview
  15
• 1.3 Hydraulic clutch system - assembly overview
  17
• 1.4 Clutch release mechanism - assembly overview
  19
• 1.5 Support shell - remove and install
  20
• 1.6 Clutch position sender G476 - remove and install
  21
• 1.7 Pedal return spring - remove and install
  23
• 1.8 Clutch drive pedal - remove and install
  25
• 1.9 Clutch drive pedal support - remove and install
  26
• 1.10 Clutch transmitter cylinder - remove and install
  29
• 1.11 Clutch slave cylinder - remove and install
  30
• 1.12 Clutch drive system line - remove and install
  33
• 1.13 Hydraulic clutch mechanism - bleed
  35
• 1.14 Clutch release mechanism - repair
  37
• 2 Clutch
  39
• 2.1 Clutch - assembly overview
  39
• 2.2 Clutch - remove and install
  39
• Controls, housing
  45
• 1 Selector mechanism - adjust
  45
• 1.1 Selector mechanism - assembly position
  45
• 1.2 Selector mechanism - component overview
  46
• 1.3 Gear knob and selector cover - assembly overview
  46
• 1.4 Gear knob - remove and install
  47
• 1.5 Gear selection mechanism - assembly overview
  49
• 1.6 Gear selection mechanism - remove and install
  51
• 1.7 Selector mechanism - adjust
  59
• 1.8 Selector rod seal - replace
  62
• 1.9 Gear selection - check
  63
• 2 Gearbox - remove and install
  64
• 2.1 Gearbox - remove
  64
• 2.2 Gearbox - installation
  75
• 2.3 Specified gearbox torque
  82
• 3 Assembly mountings
  83
• 3.1 Assembly mountings - assembly overview
  83
• 4 Gearbox - transport
  86
• 5 Fastening on the engine/gearbox bracket
  87
• 6 Gearbox - disassemble and assemble
  88
• 6.1 Gearbox - assembly overview
  88
• 6.2 Gearbox - overview
  89
• 6.3 Gearbox and 5th/6th housing cover - assembly overview
  89
• 6.4 Clutch housing - assembly overview
  91
• 6.5 Axles, differential, selector mechanism - assembly overview
  92
• 6.6 Selector rod - assembly overview
  94
• 6.7 Selector forks - assembly overview
  95
• 6.8 Selector forks - repair
  96
• 6.9 Selector rod - repair
  101
• 6.10 Selector rod seal - replace
  104
• 6.11 Gearbox - disassemble and assemble
  105
• 7 Gearbox and clutch housings
  126
• 7.1 Transmission housing and transmission housing - assembly overview
  126
• 7.2 Transmission housing cover - assembly overview
  128
• 7.3 Transmission housing cover - repair
  129
• 8 Gearbox oil
  131
• 8.1 Check gearbox oil level
  131
• Gears, shafts
  133
• 1 Input shaft
  133
• 1.1 Input shaft - general overview of assembly
  133
• 1.2 Input shaft - disassemble and assemble
  136
• 1.3 Input shaft seal - replace
  147
• 2 Output shaft
  149
• 2.1 Output shaft - general overview of assembly
  149
• 2.2 Output shaft - disassemble and assemble
  152
• Final drive - differential
  160
• 1 Seals
  160
• 1.1 Seals - assembly overview
  160
• 1.2 Left drive flange seal - replace
  160
• 1.3 Right drive flange seal - replace
  163
• 2 Differential
  167
• 2.1 Differential - general overview of assembly
  167
• 2.2 Differential - disassemble and assemble
  169
• 2.3 Differential - adjust
  175